Belt-Way Scales Conveyor Belt Scale, Model 40, Model 50, Model 100, Model 200 Product Manual

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Belt-Way Scales, Inc.

Conveyor Belt Scale

Product Manual

Belt-Way Scales, Inc.

1 Beltway Rd.

Rock Falls, IL 61071 USA

Phone: [phone]

www.beltwayscales.com

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Safety and Warnings

All Belt-Way components MUST be used as described in this manual!
Please note the labels on the integrator and in the manual denote

dangerous voltage. Failure to take safety precautions may result in
serious injury or death.

The protective conductor terminal (Earth Ground) is

signified by the following label.

It must be properly connected to earth ground per local electrical codes.

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Table of Contents

Scale Accessories ................................................................... 6

Integrator Specifications ...................................................... 7-9

Mechanical Installation ...................................................... 10-16

Integrator Installation ........................................................ 17-22

Integrator Board .................................................................................................................................... 18

Sensor and Power Wiring ....................................................................................................................... 19

Sensor Board ......................................................................................................................................... 20

Terminal Board with AC Power Supply .................................................................................................... 21

Terminal Board with DC Power Supply.................................................................................................... 22

Integrator Configuration .................................................... 23-36

Setup Wizard .................................................................................................................................... 24-25

Scale Setup ............................................................................................................................................ 26

Scale Calibration .................................................................................................................................... 27

Zero Calibration ......................................................................................................................... 27

Test Weight Calibration ......................................................................................................... 28-29

Material Test Calibration ............................................................................................................ 30

Totals and Diagnostics ....................................................................................................................... 31-33

Scale Totals ................................................................................................................................ 31

Scale Diagnostics........................................................................................................................ 31

Device Setup ..................................................................................................................................... 34-35

Plant Connect ............................................................................................................................ 35

Administration ....................................................................................................................................... 36

Routine Maintenance ............................................................. 37

Troubleshooting ............................................................... 38-39

Product Warranty .............................................................. 40-41

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Conveyor Belt Scale

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Introduction

The Belt-Way conveyor belt scale is a highly accurate and cost effective in­motion weighing system. It is designed to measure material flow over a
conveyor belt in real-time. The primary components are the integrator (AKA,
controller, display, indicator), load cell assemblies, and speed sensor. The
scale system processes speed and load signals to accumulate weight and
calculate flow rate.

This manual covers the following belt scale models:

• Model 45, Model 50 (Low capacity)

• Model 100, Model 150, Model 200 (Medium capacity)

• Model 350, Model 500, Model 1000 (High Capacity)

This manual pertains to scales operating on firmware 6.43 and above.
A manual for previous versions may be found at beltwayscales.com

BELT
LOAD

BELT

SPEED

ACCUMULATED

WEIGHT

+

FLOW RATE

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Scale Accessories

The Belt-Way conveyor belt scale works with a range of accessories
designed to maximize accuracy, efficiency, and safety.

Visit beltwayscales.com or call us today for a complete list of all the
accessories that Belt-Way has to offer.

• Angle Sensor

The angle sensor eliminates the need for constant recalibration
when the scale is installed on a variable angle conveyor or portable
machine.

• Junction Box

A junction box can be installed on the conveyor to place
the scale integrator up to 1000 ft. from the scale.

• IO Board

The IO board allows the scale to interface with a PLC system, automate
loadout of trucks and rail cars, or control a VFD to blend multiple
products.

• Outdoor Protection Enclosure

Heavy duty enclosure offers extra protection for the scale integrator.
Includes power switch.

• Wireless Multi-Scale Remote Display

The remote display allows multiple scales to be viewed from one
location. Monitor production, clear weight, and perform zero calibrations.
Wireless communication makes installation simple and cost effective.

• Plant Connect - Online Scale Production Reporting

Our Plant-Connect website allows users to monitor belt
scale production on a PC, tablet or smart phone.

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Integrator Specifications

Replacement Part Number: BWINT

100-240 AC Power Supply Factory Installed Part Number: BWPS-AC

100-240 AC Power Supply Field Installation Kit Part Number: BWPSKIT

IO Option Board Part Number: BWIO (Factory Installed)

IO Option Board Kit Part Number: BWIOKIT (Field Installed)

Display: 4.3" Color LCD

Enclosure: Cast Aluminum

Operating Temperature: -20C to 45C

Required Power: 12-24 VDC, 55 Watts

optional 110/240 AC power adapter

Inputs: 8 Load Cells (millivolts)

1 Speed Sensor (0-5 VDC Pulse)

1 Angle Sensor (0- 4 VDC)

Outputs: 1 RS232 (Printer Port)

1 RS232 (Display Port)

1 Ethernet Port (Modbus TCP)

1 USB 2.0 Client

Optional IO Outputs:

4-20 mA outputs (Tons Per Hour)

Digital Pulsed Output (Total Weight)

Min / Max Speed

Min / Max Tons Per Hour

Zero Calibration

Loadout

Optional IO Inputs:

Clear Weight

Print Ticket

Zero Calibration

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Electrical Ratings

Input Power to

Belt-Way Integrator:

12-30 VDC, 24 VDC 2.25A Max

AC Power option:

Input:100-240VAC 50/60Hz, 1A Max
Output: 24VDC, 2.25A Max

Use of the factory supplied AC Power option is recommended.

AC control power over-current protection with isolated circuit, and

disconnect point such as a breaker or switch box, is recommended

Conformance to local electrical codes is required.

Digital Inputs: (IO

option installed)

12-24VDC, 50mA sink

Digital Outputs: (IO

option installed)

12 - 24VDC, 100mA sink

Analog Outputs: (IO

option installed)

4-20mA, 24VDC powered loop

Relay Outputs, UL

contact ratings:

(IO option installed)

220VDC, 0.24A, 60W
125VDC, 0.24A, 30W
250VAC, 0.25A, 62.5VA
125VAC, 0.5A, 62.5VA
30VDC, 2A, 60W

Environmental

▪ Temperature: Normal operating range -20⁰C to +45 ⁰C.
▪ Humidity: The unit is suitable for outdoor use.

▪ Altitude: The unit is suitable for use to elevation of 2000m.

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Scale Components

The single idler scale consists of the following components

1 - Integrator

2 - Load Cell

Assemblies

2 - Mounting pipes

1- Hardware Kit

1 - Speed Sensor with
mounting arm

The dual idler scale consists of the following components

1 - Integrator

4 - Load Cell

Assemblies

4 - Mounting pipes

2 – Hardware Kits

1 - Speed Sensor with

mounting arm

Unpacking the Scale

Each scale is comprised of at least three boxes

26” x 10” x 8” - Integrator and Speed Sensor

26” x 10” x 8” - Load Cells and Hardware kit

48”, 60” or 72” long boxes for mounting pipe

and various sizes for angle sensors and other accessories

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Mechanical Installation

2D component and installation drawings are available at beltwayscales.com

3D drawings are available by request.

A. Recommended Tools

▪ Cutting torch and grinder (remove idler mounting feet)
▪ Heavy duty drill or magnetic drill press (drill u-bolt holes)
▪ Tape Measure (measure idler distance)
▪ Angle finder or phone app (measure conveyor angle)
▪ 1/2” socket and wrench (load cell and speed sensor brackets)
▪ 9/16” deep socket and wrench (V-block, u-bolts, leveling bolts)
▪ String (to level weighbridge idlers)
▪ Shim kit (to adjust idler height)
▪ 4 way screwdriver (integrator mounting, integrator door, hose clamps)
▪ Small Belt-way screwdriver (integrator wiring)

B. Conveyor Design Recommendations

The following design suggestions are essential for best scale accuracy and repeatability.

▪ Reduce speed whenever possible to maximize belt load. Slow moving, heavily loaded belts
work better than fast moving, lightly loaded belts.
▪ Proper belt tension must result in 1%-2% deflection between idlers.
For example, 2% deflection is 1 inch sag in the belt over a 4 ft. idler spacing.

▪ Lower trough angles, 0-35, are preferred. Avoid 45 troughed idlers.
▪ Install a belt scraper to keep the belt clean.
▪ Cover the conveyor to shelter it from wind, rain and snow.

MOUNTING PIPE

AND

LEVELING

PLATES

MODIFIED

CEMA IDLER

LOAD CELL

ASSEMBLIES

SPEED

SENSOR

V-Block

CONVEYOR

FRAME

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C. Scale Placement

▪ Install the scale where it is easily accessible for maintenance purposes.
▪ Choose a very rigid section of conveyor such as an idler over a brace.
▪ Avoid curves in the conveyor.
▪ Stay at least three idlers away from the head pulley, tail pulley, and loading points.

Material must not impact the belt near the scale!

D. Define the Weighbridge

▪ The weighbridge idlers must be in good mechanical condition.

▪ The weighbridge idlers must be the same trough angle, and diameter.
▪ The weighbridge idlers should be an equal distance apart.
▪ Skirting should not make contact with the belt in the weighing area.
▪ A single idler weighbridge consists of 5 idlers.

Scale must be installed on the center idler

▪ The dual idler weighbridge consists of 6 idlers.

The scale must be installed on the 2 center idlers.

GOOD

AVOID

AVOID

5 Idler Weighbridge
Single Idler Scale

6 Idler Weighbridge
Dual Idler Scale

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E. Attach Load Cell Assemblies to idler

▪ Bolt the load cell assemblies to the idler as shown using the “V-Block”.
▪ The load cell cable should point downhill.
▪ Leave plenty of clearance between the load cell assembly and conveyor frame.
▪ Do not overtighten the V-Block bolts.
▪ The bolts should be tightened ¼ turn after compressing the lock washer.
▪ Position the load cell assemblies an equal distance from the conveyor frame.
▪ This balances the load of the belt evenly between the load cells.

NOTE: Stainless Steel Load Cells – Do not use a full thread bolt,

or over tighten the existing V-Block bolt on a stainless steel load cell.

This will damage the load cell cable.

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F. Install Scale Support Pipes

This step is extremely important to ensure long term scale accuracy.

▪ The mounting pipe must touch the strap on the uphill side of load cell assembly.
▪ The strap on the downhill side must create an oval opening.
▪ Center the pipe in the oval hole.
▪ The load cell assembly must be free to move up and down slightly on the pipes.

This eliminates torque on the conveyor frame, which allows automatic alignment
of the weighing elements.

▪ Install the four hose clamps onto the pipe with the screw fitting directly over the

top of the pipe, but do not tighten the clamps at this time.

Uphill side:

Retaining strap

fits tightly around the pipe.

Downhill side:

Retaining strap

forms oval hole around the pipe.

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Conveyor Belt Scale

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G. Drill U-bolt Holes

▪ Use the leveling plate as a drill template for the U-bolts.
▪ The centers of the leveling plates and pipes should measure 15” apart.
▪ The holes should be at least 7/ 16 ” to clear the 3/8” -16 U-bolts.

H. Remove and Modify Idler

▪ Unbolt idler from frame.
▪ Remove the idler mounting feet to create clearance above the conveyor frame.
▪ If the idler feet are not removed, all other weighbridge idlers must be shimmed up 3/8”.
▪ Ensure the idler is centered on the conveyor.

15”